US8440279B2 - Structural element for a motor vehicle, and a method of fabricating such an element - Google Patents

Structural element for a motor vehicle, and a method of fabricating such an element Download PDF

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Publication number
US8440279B2
US8440279B2 US11/790,154 US79015407A US8440279B2 US 8440279 B2 US8440279 B2 US 8440279B2 US 79015407 A US79015407 A US 79015407A US 8440279 B2 US8440279 B2 US 8440279B2
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Prior art keywords
cross
rings
upright
section
metal
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US11/790,154
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US20080038576A1 (en
Inventor
Caroline Riviere
Claude Laurent
Sébastien Berne
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Flex N Gate France SAS
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Faurecia Bloc Avant SAS
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Application filed by Faurecia Bloc Avant SAS filed Critical Faurecia Bloc Avant SAS
Assigned to FAURECIA BLOC AVANT reassignment FAURECIA BLOC AVANT ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: BERNE, SEBASTIEN, LAURENT, CLAUDE, RIVIERE, CAROLINE
Publication of US20080038576A1 publication Critical patent/US20080038576A1/en
Priority to US12/770,235 priority Critical patent/US8133424B2/en
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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D25/00—Superstructure or monocoque structure sub-units; Parts or details thereof not otherwise provided for
    • B62D25/08—Front or rear portions
    • B62D25/082—Engine compartments
    • B62D25/084—Radiator supports
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/14311—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles using means for bonding the coating to the articles
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B62—LAND VEHICLES FOR TRAVELLING OTHERWISE THAN ON RAILS
    • B62D—MOTOR VEHICLES; TRAILERS
    • B62D29/00—Superstructures, understructures, or sub-units thereof, characterised by the material thereof
    • B62D29/001—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material
    • B62D29/004—Superstructures, understructures, or sub-units thereof, characterised by the material thereof characterised by combining metal and synthetic material the metal being over-moulded by the synthetic material, e.g. in a mould
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B29C2045/14213—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure deforming by gas or fluid pressure in the mould cavity
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29C—SHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C45/00—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor
    • B29C45/14—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles
    • B29C45/1418—Injection moulding, i.e. forcing the required volume of moulding material through a nozzle into a closed mould; Apparatus therefor incorporating preformed parts or layers, e.g. injection moulding around inserts or for coating articles the inserts being deformed or preformed, e.g. by the injection pressure
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29K—INDEXING SCHEME ASSOCIATED WITH SUBCLASSES B29B, B29C OR B29D, RELATING TO MOULDING MATERIALS OR TO MATERIALS FOR MOULDS, REINFORCEMENTS, FILLERS OR PREFORMED PARTS, e.g. INSERTS
    • B29K2705/00—Use of metals, their alloys or their compounds, for preformed parts, e.g. for inserts
    • B29K2705/02—Aluminium
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B29—WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29L—INDEXING SCHEME ASSOCIATED WITH SUBCLASS B29C, RELATING TO PARTICULAR ARTICLES
    • B29L2031/00—Other particular articles
    • B29L2031/30—Vehicles, e.g. ships or aircraft, or body parts thereof
    • B29L2031/3002—Superstructures characterized by combining metal and plastics, i.e. hybrid parts
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/12—All metal or with adjacent metals
    • Y10T428/12292—Workpiece with longitudinal passageway or stopweld material [e.g., for tubular stock, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y10—TECHNICAL SUBJECTS COVERED BY FORMER USPC
    • Y10T—TECHNICAL SUBJECTS COVERED BY FORMER US CLASSIFICATION
    • Y10T428/00—Stock material or miscellaneous articles
    • Y10T428/13—Hollow or container type article [e.g., tube, vase, etc.]
    • Y10T428/1352—Polymer or resin containing [i.e., natural or synthetic]

Definitions

  • the present invention relates to a structural element for a motor vehicle, the element being of the type comprising:
  • WO 2004/056610 describes a structural element for a motor vehicle, the element comprising a metal tube and a body of plastics material overmolded on the tube.
  • the plastics material body is connected to the tube firstly by buttons of plastics material situated inside the tube and formed through openings in the tube, and secondly by portions surrounding the tube.
  • connection of the plastics material body to the tube requires both first openings to allow the buttons to pass to the inside of the tube, and secondly second openings situated facing the first openings to enable moving portions of the mold to be inserted into the tube so as to form the buttons inside the tube.
  • first and second openings reduce the overall strength of the structural element.
  • fabrication requires a mold that is made complicated by the fact that it includes moving parts.
  • An object of the invention is to propose a structural element of improved strength and that is easy to fabricate.
  • the invention provides a structural element of the above-specified type, characterized in that, in any cross-section of the metal first body, the plastics material second body is situated entirely outside the outline of the metal first body, and the ratio of the axial length of each ring over the longitudinal distance between the rings, is less than 1.
  • the structural element includes one or more of the following characteristics, taken in isolation or in any technically feasible combination:
  • the invention also provides a motor vehicle including a structural element as defined above.
  • the invention also provides a method of fabricating a structural element comprising a hollow elongate first body made of metal and of closed cross-section, and a continuous second body of plastics material overmolded on the metal first body, in which the plastics material second body is connected to the metal first body by overmolding at least two longitudinally spaced-apart rings of the plastics material second body onto the metal first body, each ring surrounding the metal first body, the method being characterized in that, in any cross-section of the metal first body, the plastics material second body is situated entirely outside the outline of the metal first body, and the ratio of the axial length of each ring over the longitudinal distance between the rings is less than 1.
  • the method includes one or more of the following characteristics, taken in isolation or in any technically feasible combination:
  • FIGS. 1 and 2 are respectively a face view and a perspective view of a structural element in accordance with the invention
  • FIG. 3 is a fragmentary view on a larger scale of a zone III in FIG. 1 ;
  • FIGS. 4 and 5 are section views on IV-IV and V-V of the FIG. 1 structural element.
  • the structural element 2 comprises a tubular metal top cross-member 4 that extends substantially horizontally along a longitudinal line L of the cross-member 4 , together with two side uprights 6 made of plastics material and that extend substantially vertically.
  • the two uprights 6 are spaced apart laterally from each other, and they extend downwards from the cross-member 4 .
  • Such a structural element 2 constitutes a front face for a motor vehicle, and it is designed to be mounted at the front of a motor vehicle to support various pieces of equipment such as headlight units, an electric fan unit, a radiator, condenser, . . . .
  • the uprights 6 define between them a central space 8 for receiving a radiator, a condenser, and an electric fan unit, for example.
  • the end portions 10 of the cross-member 4 co-operate with support plates 12 of the uprights 6 that extend laterally outwards to define spaces 14 for receiving headlight units.
  • the cross-member 4 has a central upright 16 extending laterally, with end portions 10 that slope rearwards relative to the central portion 16 .
  • the line L is curved. In a variant, the line L is straight.
  • each upright 6 has a connection portion 18 connecting the upright 6 with a corresponding segment 20 of the cross-member 4 that is situated longitudinally between one of the end portions 10 and the central portion 16 .
  • the segments 20 are spaced apart laterally.
  • Each portion 18 includes a group of rings 24 , in this case six rings, that are spaced apart along the line L, each ring 24 surrounding the corresponding segment 20 , and also includes plates 26 , each plate 26 extending vertically downwards from a corresponding ring 24 to connect said ring to the remainder of the upright 6 .
  • each upright 6 is continuous.
  • each upright 6 is a single piece, and its various portions are integrally molded with one another.
  • the rings 24 of each upright 6 are integrally molded with one another.
  • the cross-member 4 presents a cross-section of closed outline.
  • the cross-member 4 thus possesses a high level of mechanical strength.
  • the cross-member 4 in each of its segments 20 possesses a cross-section that is circular ( FIG. 4 ), whereas outside the segments 20 , its cross-section is non-circular ( FIG. 5 ), in this example it is trapezoidal.
  • the cross-section is non-circular in the end portions 10 and in the central portion 16 .
  • Each segment 20 possesses a cross-section that is constant.
  • a segment 20 may have overmolding segments of circular cross-section that are separated by intermediate segments of some other section, e.g. a non-circular section, with each ring being overmolded on a corresponding overmolding segment.
  • each ring 24 and more generally each upright 6 lies in the cross-section of the corresponding segment 20 outside the outline of that segment 20 .
  • Each upright 6 is thus overmolded onto the outside of the corresponding segment 20 without an opening being formed between the inside and the outside through the segment 20 .
  • the cross-member 4 does not have any openings, and in particular it does not have any openings in the segment 20 .
  • the cross-member 4 might possibly be provided with holes 22 for fastening accessories to the cross-member, but these holes 22 are of small size, and they are located outside the segments 20 .
  • the cross-member 4 is made of aluminum, for example, then it has a thickness lying in the range 2 millimeters (mm) to 4 mm, or if it is made of steel, then it has thickness lying in the range 1 mm to 2.5 mm.
  • FIG. 3 shows the portion 18 for the right upright 6 (i.e. on the left in FIGS. 1 and 2 ), the rings 24 of an upright 6 possess a length l in the longitudinal direction, that is identical for all of the rings, in this example.
  • Each ring 24 is spaced apart from the or each adjacent ring 24 by a certain longitudinal distance e or el.
  • the cross-member 4 is made from a cylindrical tube of section that is substantially circular and identical to that of the segment 20 by placing the tube in a hydroforming mold, and by deforming the tube radially outwards by applying uniform pressure inside the tube so as to give it, outside the segment 20 , a section that is different, depending on the stiffness desired for the cross-member 4 .
  • the cross-member 4 is placed in a molding chamber having edges 30 close to the portion 18 of the upright 6 that are represented diagrammatically by chain-dotted lines C, and the plastics material is injected under pressure into the chamber in order to form the one-piece upright 6 .
  • edges 30 define the sealing boundary between the inside and the outside of the molding chamber.
  • Each portion 18 includes lateral rings 24 having the other rings 24 of the portion 18 situated between them.
  • Each lateral ring 24 is spaced longitudinally apart from the nearer edge 30 by a longitudinal distance d.
  • the ratio R of the length l of each ring 24 of an upright 6 over the distance e or el between that ring 24 and the or each adjacent ring 24 of the upright 6 is less than 1.
  • the ratio R is preferably less than 0.6.
  • the ratio F of the length f of each lateral ring 24 over the longitudinal distance d to the nearer edge 30 is greater than 0.3, and preferably greater than 0.4, in particular when using steel.
  • Complying with the ratios R and/or F serves to limit the risk of collapse, while nevertheless ensuring that the cross-member 4 is sufficiently covered in the plastics material to ensure a satisfactory connection between each upright 6 and the cross-member 4 .
  • the ratio R is preferably greater than 0.2 in order to ensure a satisfactory connection between each upright 6 and the cross-member 4 .
  • the cohesion obtained between the plastics material and the cross-member 4 serves to avoid each ring 24 turning relative to the corresponding segment 20 about the line L.
  • each upright 6 to the cross-member 4 solely by means of rings 24 surrounding the outside of the cross-member 4 avoids the need to form openings, in particular in the segments 20 , thereby conserving the strength of the cross-member 4 .
  • the rings 24 are overmolded in simple manner without any mold portions needing to be inserted inside the cross-member 4 .
  • the edges 30 are situated at the longitudinal ends of the segment 20 , close to the transition between the circular section (segment 20 ) and the section that is non-circular (trapezoidal).
  • the edges 30 are situated in register with a circular section.
  • a “hybrid” structural element i.e. an element made both of metal and of plastics material overmolded on the metal, that can be obtained easily and that presents satisfactory strength.
  • the invention applies to the front faces and more generally to any structural element of motor vehicles.

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  • Engineering & Computer Science (AREA)
  • Mechanical Engineering (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Transportation (AREA)
  • Architecture (AREA)
  • Structural Engineering (AREA)
  • Manufacturing & Machinery (AREA)
  • Body Structure For Vehicles (AREA)
  • Motor Or Generator Frames (AREA)
  • Injection Moulding Of Plastics Or The Like (AREA)
  • Manufacture Of Motors, Generators (AREA)
  • Shafts, Cranks, Connecting Bars, And Related Bearings (AREA)
US11/790,154 2006-04-25 2007-04-24 Structural element for a motor vehicle, and a method of fabricating such an element Active 2031-07-02 US8440279B2 (en)

Priority Applications (1)

Application Number Priority Date Filing Date Title
US12/770,235 US8133424B2 (en) 2006-04-25 2010-04-29 Structural element for a motor vehicle, and a method of fabricating such an element

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
FR0603682 2006-04-25
FR0603682A FR2900123B1 (fr) 2006-04-25 2006-04-25 Element structurel pour vehicule automobile et procede de fabrication d'un tel element.

Related Child Applications (1)

Application Number Title Priority Date Filing Date
US12/770,235 Division US8133424B2 (en) 2006-04-25 2010-04-29 Structural element for a motor vehicle, and a method of fabricating such an element

Publications (2)

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US20080038576A1 US20080038576A1 (en) 2008-02-14
US8440279B2 true US8440279B2 (en) 2013-05-14

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US11/790,154 Active 2031-07-02 US8440279B2 (en) 2006-04-25 2007-04-24 Structural element for a motor vehicle, and a method of fabricating such an element
US12/770,235 Active US8133424B2 (en) 2006-04-25 2010-04-29 Structural element for a motor vehicle, and a method of fabricating such an element

Family Applications After (1)

Application Number Title Priority Date Filing Date
US12/770,235 Active US8133424B2 (en) 2006-04-25 2010-04-29 Structural element for a motor vehicle, and a method of fabricating such an element

Country Status (8)

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US (2) US8440279B2 (de)
EP (1) EP1849686B1 (de)
CN (1) CN101092112B (de)
AT (1) ATE415330T1 (de)
DE (1) DE602007000279D1 (de)
ES (1) ES2317632T3 (de)
FR (1) FR2900123B1 (de)
PL (1) PL1849686T3 (de)

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US20130113225A1 (en) * 2011-10-20 2013-05-09 GM Global Technology Operations LLC Support device
US9162714B2 (en) 2011-10-14 2015-10-20 Daimler Ag Front end module

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FR2884214B1 (fr) * 2005-04-07 2007-07-06 Faurecia Bloc Avant Element structurel pour vehicule automobile, vehicule automobile correspondant, et procede de fabrication d'un tel element structurel.
FR2898855B1 (fr) * 2006-03-24 2009-02-27 Valeo Systemes Thermiques Face avant pour vehicule automobile du type composite metal/plastique
DE102007017415B4 (de) * 2007-04-13 2016-06-02 Daimler Ag Verbundbauteil aus einem mittels Innenhochdruck umgeformten Hohlprofil und zumindest einem Spritzgusselement
FR2925871B1 (fr) * 2007-12-26 2010-06-04 Plastic Omnium Cie Traverse surmoulee formant une piece structurelle et face avant technique de vehicule automobile
FR2925862B1 (fr) * 2007-12-26 2012-05-25 Plastic Omnium Cie Ensemble d'un moule et d'une traverse et face avant technique de vehicule automobile
DE102009010345A1 (de) * 2009-02-25 2010-08-26 Hbpo Gmbh Frontendmodul für Fahrzeuge
DE102010014510A1 (de) * 2010-04-10 2011-10-13 Daimler Ag Tür für einen Kraftwagen und Verfahren zu deren Herstellung
DE102010014538B4 (de) 2010-04-10 2023-01-19 Mercedes-Benz Group AG Querträger, insbesondere Instrumenten-Querträger
DE102010053957B4 (de) 2010-12-09 2025-01-23 Mercedes-Benz Group AG Verfahren zum Herstellen eines Hybridbauteils durch Vorfixierung entsprechender Bauteile und nachträglichem Versehen mit Kunststoff sowie Hybridbauteil
FR3029824B1 (fr) * 2014-12-16 2017-06-09 Tristone Flowtech Solutions (Tfs) Ensemble tubulaire thermoplastique comportant un element fonctionnel surmoule et son procede de fabrication
FR3037553B1 (fr) * 2015-06-22 2019-05-17 Valeo Systemes Thermiques Structure de support pour un module de face avant d'un vehicule automobile et module de face avant comprenant ladite structure de support
CN105522909B (zh) * 2015-12-11 2018-04-03 重庆长安汽车股份有限公司 一种汽车散热器托架结构
FR3053305B1 (fr) * 2016-06-30 2019-04-05 Valeo Systemes Thermiques Structure pour face avant de vehicule automobile
CN109177067A (zh) * 2018-11-20 2019-01-11 深圳市银宝山新科技股份有限公司 塑包钣金制件复合成型模具
CN109911022A (zh) * 2019-03-19 2019-06-21 北京长城华冠汽车科技股份有限公司 一种水箱框架和车辆
CN113844577A (zh) * 2020-06-26 2021-12-28 Tvs电机股份有限公司 用于机动车辆的复合安装支架及其制造方法
GB2599922B (en) * 2020-10-14 2024-10-23 Nissan Motor Mfg Uk Ltd Cross-car beam for a vehicle

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Cited By (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
US9162714B2 (en) 2011-10-14 2015-10-20 Daimler Ag Front end module
US20130113225A1 (en) * 2011-10-20 2013-05-09 GM Global Technology Operations LLC Support device
US9227584B2 (en) * 2011-10-20 2016-01-05 GM Global Technology Operations LLC Support device

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US20100207296A1 (en) 2010-08-19
CN101092112A (zh) 2007-12-26
DE602007000279D1 (de) 2009-01-08
PL1849686T3 (pl) 2009-05-29
US20080038576A1 (en) 2008-02-14
CN101092112B (zh) 2011-08-17
FR2900123B1 (fr) 2009-02-06
ATE415330T1 (de) 2008-12-15
EP1849686B1 (de) 2008-11-26
FR2900123A1 (fr) 2007-10-26
US8133424B2 (en) 2012-03-13
EP1849686A1 (de) 2007-10-31
ES2317632T3 (es) 2009-04-16

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